A Detail Sander for 3D Prints

Although this E Series toothbrush model has been upgraded by sonicare to a mechanical version, I think these old versions can still be purchased as can the brush heads. I would not retry this with the mechanical version myself because if the head itself were to contact the model, it might damage the model. When the magnetic version makes contact it does not do any damage.

As a purveyor of FUD and FXD designs from Shapeways. I have been trying to find a way to sand smooth printing striation (alias), and support artifacts for a much improved surface prior to painting.

I came up with the following and maybe it will also help others.

Below is an old Sonicare brand, E Series sonic toothbrush with it’s brush head. These are magnetically driven, with no mechanical device between the head and handle. As you can see, the upper brush head has had the bristles trimmed off, sides flattened, and a single plane left where the bristles were.

Using Scotch brand foam double stick tape, align one edge along any sandpaper on its non abrasive side across the entire width of the sandpaper. Press firmly. Use a knife to trim the sandpaper excess using a knife along the edge of the tape as a guide. Obviously any grit can be used. I have paper ranging from black 220 to Tamiya 15000 (white 440 shown).

Next I trim off a piece approximately as wide as the modified brush head. Shapes on the end can be added to get into tight spaces (if left overhanging off the end of the brush head).

Peel off backing and press the sandpaper piece onto the flat side of the head, note the tip is overhanging the end.

This is before sanding image of a highly contoured print and is the opposite side of the model from the next image

This is an after sanding image of the opposite side image from above, using 220:grit. I plan on running 440 grit offer that, and 600 if necessary prior to paint.

As you can see, the sander did an excellent job (in a VERY short time I might add) removing the support artifacts and also smoothing the alias on the barrel of the boiler shell. This model is printed in FXD, horizontal i.e. parallel to the build plate. so the alias is pretty pronounced.

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